Case loader



Jan. 14', 195.8` A, F, HENDRICKS ET AL 2,819,576

CASE LOADER f 13 Sheets-Sheet l Filed Sept. `22. 1954 A. F. r-naumlcKsr ET AL 2,819,576

CASE LOADER Jan. 14, 1958 Filed sept. 22, 1954 15 Sheets-Sheet 2 'I imimmf Jn- 14, 1958 A. F. HENDRlcKs ETAL 2,819,576

v CASE LOADER l Filed Sepi 22,'1954 I f 15 4sheets-sheet s CASE LOADER l5 Sheets-Sheet 4 Jan- 14" 1958 A. F. HENDRICKS ET Al.

Filed sept. 221954 ya f6 Jan. 14, 1958 A, F, HENDRICKS ETAL 2,819,576

' CASE LOADER 15 Sheets-,Sheet 5 Filed sept. 22, 1954 Jan. 14, 1958 A. F. l-nahlDI-elcKsI ETAI- 2,819,576

' CASE LOADER Filed sept. 22, 1954 15 sheets-sheet e Jan. 14,1958 A.4 F. HENDRlcKs ETAL 2,819,576

` CASE LOADER Filed sept'. 22, 1954 y i5 sheets-sheet '7 Y Jan. 14, 1958 A. F. HENDRICKS ETAL 2,819,576

CASE LOADER Filed Sept. 22, 1954 l5 Sheets-Sheet 8 Jan. 14, 1958 A. F. HENDRlcKs ETAL 2,819,576

CASE LOADER Filed sept. 22', 1954 1s sheets-sheet 9 Jan. 14, 1958 A. F. l-lElmzaRlcKsI ET AL 2,819,575

` CASE LOADER v Filed Sept. 22, 1954 13 Sheets-Sheet 10 Jan. 14, 1958 F. HENDRlcKs f -ZTAL 2,819,576

CASE LOADER Filed sept'. 22, 1954 tiff.

l5 Sheets-Sheet ll Jan. 14, 1958 Filed Sept. 22, 1954 A. F. HENDRICKS ETAL CASE LOADERV 13 Sheets-Sheet 12 Jan. 14,1958 A.y F. H'ENbRlcKs ET AL 2,819,576

CASE LOADER 13 Sheets-Sheet 13 Filed sept'. 22, 1954 CASE LOADER Alvin F. Hendricks and Robert F. Wiley, Anderson, Ind.,

asslgnors to Lynch Corporation, Anderson, Ind., a corporation of Indiana Application September 22, 1954, Serial No. 457,686

16 Claims. (Cl. 53--166) This invention relates generally to a case loader, and more particularly to a novel machine for loading groups of bottles into empty cases in a continuous series of consecutive groups.

The present invention provides an improved machine for performing case loading operations similar to those disclosed and described in cio-pending Currivan and Kerker application, Serial Number 457,386, tiled September 21, 1954, having a common assignee with the present case.

It is a primary object of the present invention to provide an improved case loading machine wherein a predetermined loading pattern of bottles may be positioned and held stationary at a loading station by means of a bottlegripping head, and an empty case may be elevated upwardly around the pattern in close surrounding relation by means of a case elevator, whereby upon release of the bottles from the gripping head there will be little or no remaining height for the bottles to fall onto the case bottom in order to complete the loading of the bottles within the case.

lt is another object of this invention to provide a case loader wherein all handling operations performed with the bottle loading pattern, after its formation, are effected entirely by pneumatically controlled means.

It is a further object of this invention to provide a case loader which is entirely automatic in its operation, and which incorporates control safety means responsive to the proper performance of every machine function, whereby completely fail-safe operation is achieved.

It is still another object to provide a case loader having a novel conveyor and bottle guide section for feeding a continuous flow of consecutively abutting bottles in adjacent spaced rows, whereby a predetermined forward pattern or grouping may be separated preparatory to loading the pattern into a case, and having automatic means for relieving the forward pressure of the conveyor-fed bottles from the forward loading pattern during and after its formation.

It is still a further object of this invention to provide a case loader having a bottle lift assembly cooperating with the discharge end of the bottle feed conveyor for elevating a separated loading pattern to a position of cooperative relation with a bottle-gripping head preparatory to moving the bottle pattern to a loading station, wherein the bottle lift assembly provides a novel collapsible supporting platform which cooperates with the bottle-gripping head to effect uniform horizontal alignment of the bottle tops regardless of variation in over-all bottle height.

It is yet another object to provide a fully automatic case loader capable of eicient and reliable operation in a continuous manner despite variations in bottle size uniformity, and capable of being readily adjusted to accommodate the case loading of a wide variety of bottle sizes in a wide variety of bottle-multiple patterns.

Further objects and advantages of this invention will become apparent .as the following description proceeds and the features of novelty which characterize this innited States Patent 2,819,52'@ Patented Jan. ld,

ricc

vention will be pointed out with particularity in the claims annexed to and forming part of this specification.

A preferred embodiment of the invention is shown in the accompanying drawing, in which:

Figure 1 of the drawing is a side elevational view, partly broken away and in section to show interior detail, of a case loader machine constructed in accordance with present invention;

Figure 2 is `a top plan view of the case loader shown in Figure l;

Figure 3 is a front end elevational view of the case loader of Figures 1 and 2;

Figure 4 is a fragmentary top plan view showing the operation .of the swinging bottle guides of the machine of Figures 1 3;

Figure 5 is a fragmentary top plan view, on an enlarged scale, showing an automatic pressure relief gate for use with the bottle feed conveyor of the machine of Figures 1-3;

Figure 5a is a vertical cross-sectional view taken as indicated by the line SrL-5a on Figure 5;

Figure 6 is a vertical cross-sectional View taken as indicated by the line 6 6 on Figure 2;

Figure 7 is a vertical cross-sectional view taken as indicated by the line 7-7 on Figure 6;

Figure 8 is `a fragmentary top view, partly broken away and in section, and with parts removed,l showing details of construction of the transfer head and bottle clamp unit of the case loader;

Figure 9 is a vertical cross-sectional view taken as indicated by the line 9--9 on Figure 8;

Figure 10 is a vertical cross-sectional view taken as indicated by the line 10H10 on Figure 9;

Figure 11 is a vertical cross-sectional view taken as indicated by the line 11-11 on Figure 8;

Figure 12 is a horizontal cross-sectional view taken as indicated by the line 12-12 on Figure 1l;

Figures 13 and 14 are vertical cross-sectional views taken as indicated by the lines 13-13 and ld-l-"i, respectively, on Figure 11;

Figure 15 is a horizontal cross-sectional view taken as indicated by the line 15-15 on Figure 3;

Figure 16 is a horizontal cross-sectional View taken as indicated on line 16-16 on Figure l;

Figure 17 is a fragmentary end view in front elevation, looking in the direction indicated by the line 17--121 on Figure 16;

Figures 18 and 19 are fragmentary cross-sectional views taken as indicated by the lines 18-18 and 19-19 on Figure 16;

Figure 20 is a fragmentary vertical cross-sectional view taken as indicated by the line 20-20 on Figure 3;

Figures 21 through 25 are diagrammatic views showing the sequence of mechanical operations performed by the case loader of this invention in loading bottles into cases;

Figure 26 is a circuit diagram showing the electricai control circuit for the case loader;

Figure 27 is a diagrammatic front end view of the case loader, showing the location of the various panel boxes for mounting the electrical circuit control means on the case loader; and

Figure 28 is an Ioperating chart showing the sequence of operations for the various functions performed by the machine disclosed during a case loading cycle.

In Figures 1, 2, and 3 of the drawing we have shown a case loader machine constructed in accordance with the present invention. For convenience of discussion, we have generally indicated the maior sections of the machine by letters in the following manner. The machine frame is indicated at A. A 4bottie feed conveyor and bottle guide section is indicated at B. A mechanical drive section for the bottle feed conveyor is indie) cated at C. A bottle lift assembly adapted to receive bottles from the conveyor and guide section B, and elevate a predetermined pattern or grouping of bottles upwardly, is indicated at D. A transfer head and bottle clamp unit, operative to receive bottles elevated by the lift assembly D and carry them forwardly in suspended relation, is indicated at E. A case elevator assembly for raising an empty case r carton about the suspended bottles held by the head E is indicated at F. The case loading station, where the transfer head of unit E and the case elevator assembly F cooperate to effect case loading, is indicated at G. An empty-case feed section, a loaded-case discharge section, andthe mechanical drive for the empty-case feed section are indicated at H, l, and I, respectively.

As best seen in Figures l and 2 of the drawing, the bottle feed conveyor and 'bottle guide section of the machine are supported on a conveyor frame having vertical supporting legs 22 at its rear or receiving end, and 'being secured to a housing s-tructure portion 24 of the machine frame A adjacent its forward or discharge end. Bottom tie rails and transverse tie channels 26 provide rigid structural bracing for the conveyor frame 20.

A first pair of center guide posts 28 and a second pair of lcenter guide posts 30 are rigidly secured to the sides of the conveyor frame 20. Each pair of guide posts 28 and 30 support -a pair of relatively long guide shafts 32, which extend horizontally inwardly over the conveyor frame 20 and terminate in mounting flanges 34 which are rigidly secured to the vertical side walls of a pair `of outer guide members 36.and 38. The outer guides 36 and 38 cooperate to form a constricted, straightwalled bottle entry section and an outwardly diverging forward travel section, as clearly seen in Figure 2 of the drawing.

Guide support shafts 40 and 42 are carried by the guide posts 28 `and 30, respectively, and extend transversely across the width of the conveyor frame 20. The guide support shafts 40 and 42 carry a pair 'of guide hangers 41 and 43, which serve to iixedly position and support a center guide plate 44 between the guides 36 and 38 along the straight-walled entry section formed thereby.

A -third pair of center guide posts 46 are carried by the conveyor frame at a point slightly forward of its mid length. A pair of front guide posts 48 are carried by the conveyor frame 20 at -a point adjacent its forward or discharge end. A pair of relatively short guide shafts 50, similar to the shafts 32, are carried by the center guide posts 46 and serve to position and support a pair of outer guides 52 and 54. Third and fourth guide sup` port shafts 56 and 58 are carried by the center and front guide posts 46 and 48, and extend transversely across the width of the conveyorl frame 20. The guide support shafts 56 and 58 each carrya plurality of guide hangers 60 and 62, respectively. The guide hangers 60 and 62 serve to xedly position and support a plurality of guide plates, including a relatively long center guide plate 64, and a pair of relatively short intermediate guide plates 66 and 68.

An additional pair of guide supports 70, having relatively short guide shafts 72 provided with mounting flanges 74, serve to xedly position and support the outer guides 36 and 38 adjacent their forward ends.

The outer guides 52 and 54, and the guide plates 64, 66, and 68, are all formed as substantially straight-walled sections. The rear ends of the outer guides 52 and 54 terminate closely adjacent the forward ends of the outer guides 36 and 38, which are also substantially straight walled at this point. The outer guides, 36, -38, and 52, 54, provide a substantially continuous guide .channel adapted to confine a flow of bottlesdherebetween. i i

As best shown in ,Figureq ofthe drawing, the-'guide Fil plates 64, 66, and 68 are each provided at their rear edges with `a pair of roller brackets 76 and 77, which rotatably support a pair of rollers 78 and 79 on vertical axes. The rear edges of the guide plates 64-68 operate in the manner of spreader gates to direct the bottles into adjacent, spaced rows between the guide plates and outer guides. The rollers 78 and 79 serve to insure the movement of bottles into one row or another without risk of jamming obstruction against the edge of a guide plate. Preferably, the vertical posi-tion of the roller brackets 76 and 77 is selected so as to permit the rollers 78 and 79 to engage the bottles at points slightly above and slightly below the label L thereof, as shown, to avoid tearing or marring fthe label as the bottles are directed into rows.

A conveyor traveling level, having a movement in the direction shown by the arrow, is indicated generally at 80. The conveyor 80 comprises a plurality of link plates 82 (see Figure l) which are suitably supported in conventional manner on forward (upper) and return (lower) conveyor rails. A sprocket wheel 84 is carried by a suitable shaft 88 a-t the receiving end of the con Vey-o1. 80. The sprocket shaft 88 is suitably mounted for rotation within bearings carried by the conveyor fra-nie 20. A conveyor drive shaft 90 is rotatably supported within suitable bearings adjacent the discharge end of lthe conveyor 80. The drive shaft 90 carries a sprocket wheel 86, which together with the sprocket wheel 84, serves to engage the link plates 82 for effecting drive of the conveyor 80.

A power sprocket gear 92, also carried by the drive shaft 90, meshes with a link chain 94 driven by a gear 96 on the output shaft 98 of a gear reducer 100. A link chain 102 serves to connect an input shaft of the gear reducer with a drive sprocket gear 104 carried on an output shaft 106 of a motor 108. In this way power from the motor 108 is transmitted to effect continuous drive of the conveyor 80. The drive mechanism for the conveyor 80 is mounted upon the machine frame within the housing portion 24, and is suitably enclosed therein. A removable door panel 110 is provided for purposes of access.

The bottle feed conveyor and bottle guide section B of our case loader machine is provided with two separate means for relieving the pressure which is exerted by the tendency for forward movement of bottles on the conveyor against the forward pattern or grouping of bottles which is to be loaded into a case. First, we provide swinging bottle guides for separating a forward loading pattern from the rows of bottles being fed by the conveyor and wholly eliminating all forward feeding pressure exerted against the loading pattern by the conveyor-fed bottles. A bottle-guide swing-operating cylinder 112 is mounted on the conveyor frame 20 by means of a swing cylinder mounting bracket 114 (see Figure 7).` A guide bar bracket 116 is positioned below the swing cylinder 112. A piston rod 118 extends from the swing cylinder 112, and is pivotally attached to the upper end of a swing lever 120. The lower end of the swing lever 120 is pivotally secured to the guide bar bracket 116. The guide support shaft S8 is also pivotally secured to the lever 120 at a point intermediate the ends thereof. Suitable slide blocks and slots 122 are provided by the lever 120 for effecting adjustable pivotal attachment to the elements 118, 116, and 58.

As best seen in Figure 6 of the drawing, the guide hangers 62 are secured to the guide support shaft 58 by means of mounting blocks 126, which provide vertical pivot pins 128 for rotatably suspending the guide hangers 62. lThe guide hangers 60 of the guide support shaft 56 are similarly provided with mounting blocks 130 having pivot pins 132. The pivot pins 128 and 132 have a suciently loose fit within the guide hangers 62, and 60 points lying on `the :longitudinal axis of the guide support shaft 56.

The second means for effecting relief of bottle feeding pressure is provided in the form of a pair of automatic pressure gates. As best seen in Figure 5 of the drawing, a pair of bottle stop levers 142 and 144 are pivotally mounted on pins 146 to mounting brackets 148 and 150, respectively, The mounting brackets 148 and 150 are lixedly secured to the vertical side walls of the constricted or straight-walled entry portions of the outer guides 36 and 38. The bottles carried by the conveyor through the constricted portion of the outer guides 36 and 38 are aligned in two side-by-side rows, separated by the center guide plate 44.

The bottle stop levers 142 and 144 provide stops 152 and 154 extending at right angles from their free ends. The walls of the outer guides 36 and 3S are formed with suitable slots through which the stops 152 and 154 may extend to engage the corresponding rows of bottles and prevent forward movement thereof. Each of the bottle stop levers 142 and 144 is provided with a gate cylinder 156 having a piston 158 which carries an abutment screw 160 adapted to engage the levers 142 and 144 and pivot them inwardly across the path of travel of the bottle rows. A suitable bias spring 162 normally serves to pivot the levers 142 and 144 outwardly so as to withdraw the stops 152 and 154 and permit the free movement of bottles on the conveyor 00.

The gate cylinders 156 are pneumatically responsive, and when actuated serve to move the stops 152 and 154 inwardly to path-obstructing positions against the bias of springs 162. An air supply line 164 conducts a supply of air to each of the cylinders 156 from an air source supply line 166. The ow of air from the air source line 166 to the air supply line 164 is controlled by means of a control valve 168. A gate 170 extends through an opening in one of the guide plates 33 along the diverging wall portion thereof. The gate 170 is normally biased by means of a spring hinge 172 so as to extend inwardly through the guide plate 38 into the path of movement of the bottles carried by the conveyor 80. An adjustable limit stop 174 is provided to prevent outward swing of the gate 170 beyond a predetermined limiting position. A hinge pin 17S serves to connect the gate 170 to a piston rod 176 of a valve member 130, which is slidably movable within the gate control valve 168.

lt will be apparent from Figure 5 that the presence of a sufficient number of bottles within the diverging portion of the guide plates 36 and 3S will serve to cause the gate 170 to be engaged by adjacent bottles and pivoted outwardly through the guide plate 38. Such swinging movement of the gate 1'70 serves to axially slide the piston rod 176 and valve member 180 toward the valve-open position shown. Air may then ow freely from the air source line 166, through the air supply line 164, to the gate cylinders 156, thereby eiecting actuating movement of the stops 152 and 154 to the closed positions shown.

As best seen in Figures 2 and 4 of the drawing, a uniform flow of bottles will be conducted by the conveyor 80 in a pair of side-by-side rows through the constricted entry portion of the outer guides 36 and 38. The tworow flow of bottles will then be permitted to displace outwardly through the diverging portion of the guide plates 36 and 38 toward a four-row How, as directed by the guide plates 64, 66, and 68 in cooperation with the outer guides 52 and 54. Complete lling of the diverging conveyor portion will serve to actuate the automatic pressure gates, as shown in Figure 5 of the drawing.

It is an important feature of the present invention to provide an initially constricted and then divergent bottle ilow path toward a maximum conveyor width accomm0- dating the desired number of side-by-side rows of bottles. The particular diverging guide arrangement shown greatly CII facilitates .an even bottle How, and substantially minimizes the possibility of excessive bottle feed pressures aga1nst the forward end of the case loader under maximum capacity conditions requiring `the conveyor to receive bottles at :a faster rate than they can be carried forward and loaded into cases.

It will be apparent that the number of guide plates may be varied to provide the desired number of side-byside rows of bottles for separation into a loading pattern or grouping. In the particular construction illustrated, four rows are shown to permit the separation of `a threedeep forward grouping of twelve bottles for loading into a case. The particular arrangement shown is in tended for use in connection with the case loading of relatively large quart-size bottles. By increasing the number of guide plates, smaller bottles may be arranged, for example, in rows of six to permit the selection of a six-deep, six-row pattern of thirty-six bottles to be loaded into a case.

When the bottles have been carried to the forward end of the conveyor 80, they will be discharged onto the bottle lift assembly D, whereby a forward loading pattern of bottles may be elevated upwardly into the transfer ,head `and bottle clamp unit E for movement to the case loading station G. A lift platform is provided beyond the forward end of the conveyor 80, `and comprises a plurality of floating or collapsible bottom plugs 190 (see Figures 9 and 10). Each of the bottom plugs 190 provides a pair of bottom rails 192 adapted to engage the bottom of a bott-le and support it in a vertical position. A stern 194 (see Figure 9) supports the plug 190 and serves to enclose a spring stud 196 which is biased upwardly by means of a `spring 198. The stem 194 is suitably sup ported by means of a mounting bushing 200 lon a base plate 202. The bottom plugs 190 serve to resiliently support a plurality of bottles in vertical position, while permitting depression of the bottles for purposes of aligning the tops of bottles of diierent vertical heights in the same horizontal plane. In this manner, every bottle is uniformly positioned so as to` permit the bottle clamp unit to gra-sp each bottle at the same point with respect to the cap or crown thereof, irrespective of irregularities in the heights ofthe bottles.

The base plate 202 is supported by means of channels 204 and ya guide bracket 206 which provides edge rails 207 `cooperating with vertical guides 208 for up and down movement of the base plate 202. The piston rod 210 of `a pneumatic bottle-lift cylinder 212 is `connected to `the guide bracket 206. A suitable air supply 214 serves to actuate the bottle-lift cylinder 212 for effecting vertical reciprocation of the bottle-lift platform formed by the bottle plugs 190.

A dead plate and stop Iassembly is provided between the forward end of the conveyor' 30 `and the bottle-lift assembly. Wear plates 220, having spaced. gaps to permit liquid drainage for cleaning purposes, form a horizontal support level upon which Athe bottles are received and supported as they move from the conveyor 30 to the bottle-lift bottom plugs 190. Bottle-stop brackets (see Figures 6 and l0) serve to suspend a bottle-stop support bar 224 to which a plurality of vertical bottle stops 226 are secured. The bottle stops 226 are rigidly secured between the wear plates 220 and support bar 224 in xed positions lof alignment with the guide plates of the bottlefeed conveyor as the bottle rows move forwardly in their normal course of travel on the conveyor.

A plurality of bottle separators 228 (see Figure 9) are supported on the bottom plug base plate 202 of the bottle lift assembly in alignment with the bottle feed conveyor guide plates and the bottle stops 226. It will be apparent from Figure 2 of lthe drawing that this alignment of the guide plates, bottle stops, and bottle separators serves to direct a flow of `bottles in side-byside rows -onto the bottle liftvassembly D.

When it is desired to elevate the bottle `lift platform for raising a loading pattern toward the transfer head and bottle clamp unit E, the swinging bottle guides are actuated to relieve the backed-up bottle pressure exerted against lthe loading pattern and to stop the forward movement of bottles from the conveyor `and dead plate assembly toward the bottle lift assembly. As best seen in Figure 4 of the drawing, actuation `of the swing-operating cylinder 112 effects a simultaneous sidewise movement of the guide plates 52, 54, 64, 66, and 68 in an arcuate path about pivot points lying along the longitudinal axis of the guide support shaft 56. The foremost bottles of the rows formed between the swinging guide plates will be moved transversely across the width of the conveyor S and wear plates 220 lto a position of misalignment with respect to the foremost three-deep pattern of bottles resting on the bottle lift assembly. As the forward ends of the swinging guide plates move in an arcuate path, the foremost bottles immediately prior to the loading pattern will rotate in ya rolling movement about the bottles immediately forward of them and lagainst the vertical edge of the bottle stops 226. This rolling movement yof the bottles effectively minimizes abrasive sliding between bottles, commonly termed scrubbingj and prevents darnage to the bottle labels.

As indicated by the arrows, the bottles shown in Figure 4 will roll or rotate in a counter-clockwise direction and move sideways a distance of about one-half the `diameter of a bottle. At the same time, the rolling or rotating bottles will move slightly in a forward direction. Conversely, as the swinging bottle guides are returned to their position yof normal straight alignment after elevation and removal of a loading pattern, the foremost bottles will rotate against the edges of the bottle stops 226 in a clockwise direction, and will again move forwardly, because of bottle feed pressure, in aligned rows between the bottle stops 226 and the bottle separators 228 of the 'bottle lift assembly D. lt should be noted that the bottle feed pressure against the bottle stops 226 is prevented from exceeding a reasonable design maximum by means of the bottle stops 252 and 15,4.

The particular cooperation between the swinging guide plates and the bottle stops, resulting in `the rolling or rotational forward movement of the foremost bottles, is of particular importance and represents a substantial improvement over known methods of loading pattern separation. The structure of the present invention eliminates all possibility of bottle tip-over and breakage, and substantially eliminates scrubbing between moving machine parts or other bottles and the label of the longitudinally adjacent bottles being separated during the operation of defining and removing a loading pattern of bottles.

For the purpose of determining the presence of a full bottle pattern on the bottle-lift platform, We provide a plurality of stop lingers 230 (see Figure l0). One stop finger is provided for each row of bottles, four being required for the four-row three-deep pattern illustrated. Each stop iinger 230 is freely rotatable about a pivot pin 232. A stop finger assembly support 234 is secured to the machine frame and serves to xedly position a support bracket 236. Springs 238 serve to bias the stop lingers 230 in a vertically upward position for effecting contact with the foremost bottles of the adjacent rows, when such bottles have reached a predetermined forward position. A feeler bar 240 is rigidly carried for pivot movement by a horizontal rock shaft 242 and serves to provide a contact bracket 244 at its one end which en gages a limit switch 246.

in the normal arrangement of parts, without abutment of four bottles against all four stop fingers 230, the feeler contact bracket 244 serves to engage and hold open the limit switch 246. The switch 246 is spring biased to a closed position, but is not free to move to such position because of obstruction by the feeler contact bracket 244. As long as one stop linger is held in its vertical position relation.

by its spring 238, the spring bias of the limit switch 246 is insucient to effect movement of the feeler contact bracket 244 and allow the switch to close. When, however, a full four rows of bottles are present on the lift assembly with the foremost bottles in a predetermined forward position, all of the stop ngers 230 will be engaged and pivoted to positions of clearance with respect to the feeler bar 240, thereby permitting the feeler contact bracket 244 and feeler bar 240 to be moved by the closing bias of the limit switch 246.

In this way, the switch 246 will automatically close when a full bottle pattern is present on the lift assembly. It is apparent that the foremost bottle of each of the side-by-side rows will only etect pivoting of the stop fingers when additional bottles immediately therebehind serve to transmit a sufficient forward feed pressure. This occurs only when a full loading pattern is present on the bottom plugs which form the bottle-lift platform. Subsequent actuation of the bottle-guide swing-operating cylinder 112 will swing the rows of bottles immediately behind the loading pattern about one-half bottle diameter to one side in rolling contact about the bottle stops 226. The bottle-lift platform may thereafter be elevated a height of about 3 inches to raise the bottles supported thereon to the transfer head and bottle clamp unit E.

A transfer head is indicated generally at 250 on Figure 8, and includes a head carriage, bottle clamp unit, jaw operating drive, and transfer cylinder. A front carriage 251 and a rear carriage 252, are supported by means of horizontal and vertical axis rollers 253 and 254, respectively, on frame channel members 255. Tie means comprising a tie bar 256 and a tie rod 258 serve to rigidly interconnect the rear carriages 251 and 252 in spaced For purposes of illustration, both tie bar and tie rod arrangements are shown, but it will be understood that a pair of carriage connector means of either one type or the other would actually be employed rather than one of each as shown.

A plurality of bottle clamp units 260, 261, and 262 are supported in suspended relation from the tie means 256 and 258, and may be adjustably positioned between the front and rear carriages 251 and 252 to provide the desired bottle pattern spacing. It will be apparent that a greater number of smaller bottle clamp units may be employed where a different pattern is desired for handling bottles of smaller size. The head carriage assembly and the bottle clamp units carried thereby form the transfer head 250, and may be shifted forwardly as a unit by movement of the rollers 253 and 254 along the frame channel members 255.

The bottle clamp units 260 to 262 each comprise (as best seen in Figure ll) a housing 264 having a housing cover 266. The housing 264 is recessed to form a pair of spaced slide chambers 268 and 270 which are adapted to receive the enlarged head portions of a block slide member 272. The head portions of the block slide member 272 are each formed with a pair of cam slots 274 and 276. Cam followers 278 and 280 of clamp slide blocks 282 and 284 are received within the cam slots 274 and 276. The slide blocks 282 and 284 are received within lateral slide chambers 281 and 283 formed in the housing 264 at opposite sides of a slide retainer element 285. The slide blocks 282 and 284 iixedly carry a pair of opposed gripping jaws 286 and 288, respectively, having resilient grippers 290 adapted to engage and firmly grasp the neck of a bottle. A liber stop bar 292 is suspended between the gripping jaws 286 and 288 by a support means 294 which extends downwardly from the housing 264.

The block slide member 272 provides an actuator end 298 carrying a roller 300. A jaw clamp operating bar 302 provides an elongated roller track for cooperation with the roller 500. In this manner, a positive interconnection between the block slide member 272 and the clamp operating bar is provided, while permitting recipro cation of the transfer head in a horizontal plane. As best seen in Figures 8 and 9 of the drawing, the operating bar 302 is transversely morable on guide shafts 304, which slidably extend through suitable bosses 305 rigidly carried by the machine frame. A pair of slide knobs 306 extend upwardly from the operating bar 302 and effect open yoke connections with a pair of actuating clamp levers 308, which are rigidly connected to a rock shaft 310. Bearings 311 and 312 serve to rotatably support the rock shaft 310 in a fixed horizontal position. A power clamp lever 314 is rigidly secured to the rock shaft 310 and is connected by means of a link 316 to the piston rod 318 of a pneumatic jaw-operating cylinder 320,

It will be apparent that actuation of the jaw-operating cylinder 320 to effect reciprocation of the piston rod 313 will serve to laterally shift the jaw clamp operating ba 302, and thereby reciprocate the actuator ends 293 of the block slide members 272 of bottle clamp units 260- 262. Reciprocation of the block slide members 272 serves to slide the head portions thereof within the slide chambers 268 and 270. As best seen in Figure 12 of the drawing, movement of the block slide member 272 causes movement of the cam slots 274 and 276 of each head portion relative to the axially fixed clamp side blocks 282 and 284. The cam followers 278 and 280 will cooperate with the cam slots 274 and 276 to effect transverse sliding movement of the clamp slide blocks within the slide chambers 281 and 283. In this manner, the gripping jaws 286 and 288 may be moved toward and away from each other by reciprocation of the block slide member 272. The jaw operating cylinder 32) thereby effects simultaneous opening and closing of the gripping jaws of each of the bottle clamp units 26%*262 As best seen in Figures 13 and 14, the resilient grippers 290 of the gripper jaws 286 and 238 serve to positively engage the necks of each of the bottles therebetween. It will be apparent that the top cap surface of each bottle will be raised into abutting engagement with the fibel' stop bars 292 of the bottle clamp units as the bottles are raised by the bottle lift assembly. The resiliently mounted bottom plugs 190 which form the bottle lift platform will permit appropriate adjustment for bottles of varying heights while effecting horizontal alignment of the tops of -all bottles in a single plane. It is well-known that commercially produced bottles of a particular capacity,` although intended to be uniformly identical in shape and size, vary considerably in vertical height. The neck portions of such bottles, however, are usually substantially uniform, or at least subject to negligible variation among bottles of the same kind. By aligning the top caps in the manner described, it is possible to enable the transfer head and bottle clamp unit E to effect uniform gripping of all the bottles of a loading pattern with great reliability and a minimum hazard of bottle breakage.

It should be noted that immediately prior to jaw closing about the necks of the bottles of the loading group, the bottles of each of the spaced rows are in consecutive contacting or abutting relation. Frequently it is desirable to separate the bottles when positioned in loaded relation within a case by means of a cardboard partition grid, so as to avoid' direct bottle-to-bottle contact and minimize risk of breakage. Some initial spacing between the abutting bottles of the loading group rows may readily be `accomplished by spacing the respective gripping units longitudinally from each other a suiiicient distance so that as the bottles are gripped by the closing jaws the bottle caps will'slide against the fiber stop bars 292 and the bottles will be longtudinally spaced from each other.

The entire transfer head 250 is reciprocable in a horizontal plane from a rear or bottle gripping position directly overlying the lift platform of the bottle lift assembly to a forward or bottle releasing position directly overlying a case elevator assembly F, `to be hereinafter described in detail. Reciprocation of the transfer head 250 is effected by means of a pneumatically operated head transfer cylinder 322 (see Figure 8). A piston rod 324 is rigidly connected by means of a head flange 325 to the rear carriage 252 of the transfer head 250, and axial movement of the piston rod 324 serves to move the head assembly 250 from a bottle gripping position to a case loading position and return.

A normally open limit switch 326b (see Figure 8) is ixedly secured to the machine frame, and cooperates with one end of a trip 326 carried by the jaw clamp operating bar 302 so as to effect switch closure when the bottle-gripping jaws of the units 260262 are closed. A normally open limit switch 32601 (see Figure 8) is lixedly secured to the machine frame and cooperates with the other end of the trip 326 so as to effect switch closure when the bottle-gripping jaws are open. A normally open limit switch 327 (see Figure 9) is xedly secured to the machine frame, and cooperates with a trip 327a carried by an elongated trip bar 215 which is rigidly secured to the bottle lift platform so as to effect switch closure when the platform is in its full elevated position. A normally open limit switch 328 (see Figure S) is carried by the rear carriage 252 of the transfer head, and cooperates with a trip 328a mounted on the machine frame so as to effect switch closure when the transfer head 250 is in its full back position. A normally open limit switch 329 (see Figure 8) is carried by the front carriage 251 of the transfer head, and cooperates with a trip 329a mounted on the machine frame so as to effect switch closure when the transfer head 250 is in its full forward position. A normally open limit switch 490 (see Figures 8 and 10) is mounted on an overhanging bracket 492 secured to the jaw operating bar 302. A cooperating trip 490a is secured to the transfer head carriage tie means 256 so as to effect contacting engagement with the switch 492 only when the bottlegripping jaws are closed. Figure 8 shows the jaws in closed position, and it will be apparent that upon forward movement of the head 250 the trip 49% will effect closing of the switch 490. After release of the bottles into a case by opening of the jaws, the switch i90 and its trip 490g will no longer be in linear alignment because of lateral movement of the bracket 492 with the jaw operating bar 302, and as the transfer head moves back to a bottle-gripping or rear position the trip 4905i will not engage the switch 490. It will be apparent that as the transfer head 250 moves forwardly with a full loading pattern held by the closed gripping jaws, the switch 290 will be closed for energizing a suitable solenoid for controlling a valve to regulate a supply of compressed air to the cylinder 112.

As best seen in Figures 3 and l5, the case elevator assembly F includes a case elevator platform 330 disposed in horizontal alignment upon a pneumatic elevator lift cylinder 332. An elevator housing 334 encloses the opw erating parts of the elevator assembly and is xedly mounted on the machine frame. A back plate 336 and a pair of case guide angles 338 and 340 are iixedly secured to the supporting surface of the platform 330. The guide angles 33S and 340 are positioned in parallel spaced relation, and are adjustably mounted to permit variation of the separating distance therebetween to accommodate cases of different widths. A plurality of case bearing strips extend across the platform 330 in the direction of case movement, and further serve to support and guide the case in its movement with respect to the platform 330.

A slide plate or guide 344 is rigidly secured to the machine frame and cooperates with an elevator slide member 345 carried by the elevator platform 330 at its rear edge (see Figure 15). In this manner, the elevator platform 330 is uniformly guided during Vertical up and down movement. A bearing plate 348 carried by a piston rod 350 of the lift cylinder l332 is rigidly secured 11 to the bottom surface of the platform 330. A piston 352 serves to actuate the piston rod 350 in response to pneumatic pressure within the cylinder 332. in this way, the platform 330 may be vertically reciprocated.

A trip pin 354 is carried by the lift cylinder 332, and is vertically slidable within a guide block 356. A roller 358, carried by the trip pin 354 at its upper end, extends a slight distance upwardly through the elevator platform 33u, and is upwardly biased by a supporting spring body 36th. A contact head 362 is carried by the trip pin at its lower end, and is preferably vertically adjustable for varying the height of movement of the trip pin to accommodate operation with cases of different selected heights. A limit switch 364 is xedly mounted on the frame by means of a bracket 365. The switch is normally biased open, and will be closed in response to a predetermined downward movement of the contact head 362 thereagainst. A trip plate 368 is hingedly connected to the supporting surface of the platform 33th in a position directly overlying and lightly contacting the roller 358. It will be apparent that the presence of a case on the elevator platform 330, in a condition of suiiicient weight to exert actuating downward pressure against the trip plate 366, will serve to move the trip pin 354 downwardly and effect a closing of the limit switch 364. This condition will occur only when a full loaded case is present on the platform 33t) with the elevator in its fully lowered position.

A trip plate 368, having an assembly of trip actuating elements substantially identical with the parts 354-362 and a limit switch 369 (shown only in Figure 26), is also hingedly connected to the supporting surface of the platform 33t). The switch 369 is normally biased closed, and will be actuated to an open position when a full case is positioned on the trip plate 368. The trip plate 363 is of elongated form, and is so positioned on platform 33u as to provide an over-hanging portion extending beyond the forward edge of the platform with respect to the direction of case travel. A loaded case, therefore, will continue to engage the trip plate 363 and maintain the limit switch 369 in an open position until the case is fully olf the platform 330. An empty case does not provide suicient weight to depress the trip plate 362B the distance necessary for actuating limit switch 369 to an open position.

As best seen in Figure l5, a trip rod 370 having a pivot 372 is mounted on the platform 330 and biased by spring means 374 in an inward direction, for engagement with the side of a case when positioned on the platform 33t). The outer end of the trip rod 370 carries a contact head 376e which engages a limit switch 376, normally biased open, for actuating the switch to a closed position when a case is present on the elevator platform 330. The trip plates 366 and 358 effect an actuating movement in respense to the substantial weight of a loaded case, whereas the trip rod 370 must respond to the relatively light weight of an empty case. Frequently, the case bottoms may become wet and therefore lacking in sufcient rigidity to effect actuation of a trip plate. The case sides, however, ordinarily remain dry and have sucient structural rigidity to effect trip actuation. The trip rod 376i, therefore, is positioned so as to operate against the side of a case rather than against the bottom as in the manner of trip plates.

A normally open limit switch 378 (see Figure 3) is iixedly mounted on the machine frame, and cooperates with a trip 378i: carried by an elongated trip bar 377 which is rigidly secured to the back plate 336 of the case elevator. The trip 378:1 effects closure of the switch when the case elevator is in its full up position. A second limit switch 379 is xedly mounted on the machine at a point about midway between the lower and upper limits of the vertical stroke of the case elevator platform.; The trip 378a also serves as a trip to close 12 Y theswitch-379 when the case elevator'is at about the halfway point of its lowering travel.

- The loading station G, where the transfer head and case elevator cooperate to effect loading of the bottles into the case, includes a funnel plate assembly, funnel guide, and funnel plate guard. As best seen in Figure 3 and Figures 16 to 19, a funnel plate 380 is provided to surround and confine the bottle loading pattern as the empty case is elevated in surrounding relation about the bottles during loading. The funnel plate 380 is centrally cut away to provide an over-size peripheral outline conforming to the external contour of the bottle pattern. A plurality of cross braces 382 define the rows of the loading pattern and provide fixed support means for mounting plurality of spring fingers 384. It will be apparent that relative movement between the funnel plate 380 and the bottle loading pattern will result in resilient contact# ing engagement of each bottle by a surrounding plurality of four spring fingers 384, thereby guiding and maintaining alignment of the bottles during the loading operation.

A pair of mounting brackets 386 are xedly positioned relative to the machine frame and serve to support a pair of vertical guide rods 388. The upper ends of the brackets 386 also serve as an abutment support upon which the funnel plate 380 rests when in a lowered position. A pair of roller brackets 390 are secured to the edges of the funnel plate 380, and each carry an inwardly concave roller 392, having nylined bushings for smooth rotation about supporting roller pins 394. The rollers 392 cooperatingly engage the vertical guide rods 38S to permit smooth vertical reciprocation of the funnel plate 360. It will be apparent that as an empty case is raised by the case elevator, its upper edge will contactingly engage the funnel plate 380, thereby positioning the spring fingers 384 within the walls of the case to dene the loading positions of the bottles to be received. As a case is further elevated, the funnel plate 380 will be raised therewith, and the loading pattern of bottles will pass therethrough as the case is moved to its uppermost position of surrounding relation about the bottles. As the loaded case is lowered, the funnel plate 380 will fall with it to its lower startingposition upon the mounting brackets 386.

Although not shown in connection with the particular construction disclosed, it will be understood that a suitable limit switch and trip may be provided to discontinue operation of the machine in the event that the funnel plate 38d should stick or jam in its raised position and fail to fail to the position shown in Figure 3 after a casel loading. Obviously, the funnel plate 380 would obstruct the next loading operation, if in its raised position, causing bottle breakage and possible damage to the machine. We have found, however, that the novel guide and roller arrangement provided by the present invention for vertical sliding of the guide plate precludes any possibility of sticking or jamming in raised position, and eliminates any practical need for a safety switch arrangement.

The cases which are customarily employed for bottle loading are provided with cover flaps of various forms, which frequently present an obstruction problem during the loading operation. It is essential to prevent any possibility of a case having one or more cover aps lowered in closed position when the case is elevated to receive a bottle pattern. For this purpose, we provide a plurality of spring guides 400 (see Figures 17 and 18) which are carried by the funnel plate 380 in downwardly extending relation therefrom at its opposite ends. The guides 400 serve to engage the side of a case c and center the case in properly aligned position below the funnel` plate 380. Additional spring guides 402 are similarly 13 ing 410 surrounds the loading station G, and is pro vided with a pair of transparent side plates 412 and a front plate 414 to permit visual observation. The front plate 414 to permit visual observation. 'Ihe front plate plate 414 is mounted in a hinged door frame 416 to permit access to the loading station.

The empty-case feed section H and the loaded-case discharge section I, together with the mechanical drive for effecting case feed J, are best shown in Figure 3 of the drawing. Although the case feed arangement shown is from the right-hand to the left-hand side of Figure 3, it will be understood that the arrangement may be reversed, if desired, to provide feed in the opposite direction, from left to right.

A case feed conveyor is provided, and includes a conveyor frame 420 which is rigidly mounted on the machine frame A and is suitably supported on vertically adjustable supports 422. The conveyor frame 420 carries a fixed horizontal case plate 424, upon which the cases are supported and slid forwardly toward the case elevator during operation of the machine. A flight chain assembly is provided, and includes a set of ight chains 426, carrying a plurality of spaced flight bars 428, and mounted for driving movement on sprocket wheels carried by a drive shaft 430 and an idler shaft 432. The conveyor frame 420 also provides a pair of longitudinally extending case guides 434 and 435, which position the empty case during its movement along the conveyor, and a pair of flap guides 436 and 437, which serve to maintain the cover flaps of the case in downwardly open positions.

The mechanical drive for the case-feed conveyor includes a motor 44) having an output shaft 442 which carries a drive sprocket 444. A drive chain 446 connects the motor 440 to a clutch sprocket 448 of the clutch shaft 450 of a single revolution clutch 452 (see Figure A power gear 454 is carried by the clutch shaft 450, and meshes with a drive shaft 430. A clutch actuator means 458 provides a vertically reciprocable clutch pin 459 which is controlled by means of a solenoid 460. Energizing of the solenoid 460 serves to effect downward movement of the clutch pin 459 to permit clutch engagement, thereby enabling power to be transmitted from the motor 440 to the case feed conveyor.

A trip rod 462 is pivotally mounted on the case guide 435 and inwardly biased in the manner of trip rod 370, as

described in connection with the case elevator assembly.

The outer end of the trip rod 462 carries a contact head 462i: which engages a limit switch 466 (see Figure 2). The limit switch 466 is normally biased in closed position, and operates to energize the solenoid 460 for withdrawing the clutch pin 459 and transmitting driving power from the motor 440 to the conveyor Eight chains 426. An empty case placed on the case plate 424 will have its lower rear edge engaged by a moving flight bar 428, and will be slid forwardly along the plate 424 between the case and flap guides 435-437. As a case engages the contact head 462a of the trip rod 462, the limit switch 466 will be opened, de-energizing the solenoid 460 and permitting the spring biased clutch actuator means 458 to elevate the clutch pin 459, thereby disengaging the clutch 452 and interrupting the transmission of driving power after the completion of a single clutch shaft revolution. In this way, cases will be automatically fed only as required by the loading operation.

A case discharge conveyor is provided at the side of the caseelevator opposite the case feed conveyor. The discharge conveyor includes a roller frame 470 having a plurality of rollers 472. The frame 470 may be secured to the machine frame by means of pivot brackets (not shown) for permitting adjustment of the traveling level to any desired position of downward inclination. ln this manner, the discharge conveyor will effect gravity removal of the loaded cases away from the machine.

In order to effect controlled actuation and coordinated operation of the bottle lift platform, bottle-gripping jaws", and transfer head movement, we provide a plurality of air control valve and limit switch trips which are regulated by the up and down movements of the bottle lift and case elevators during operation of the machine. As seenA in Figure 9, the trip bar 215 which carries the limit switch trip 327e also carries an air valve trip 45M and a second limit switch trip 482m An air valve 436 is fixedly mountedv on the machine frame, and is normally biased in a valve closed position. The air valve 48? serves to control flow between a compressed air source line 484 and an air supply line 485 leading to the jaw-operating cylinder 320 at an end thereof for elfecting forward movement of the piston rod 313 and consequent closing of the bottle gripping jaws.

A limit switch 482 is lxedly mounted on the machine at a point about midway between the lower and upper limits of the vertical stroke of the bottle lift platform. The trip 482m serves to close the switch4 482 when the bottle lift is at about the half-way point of its lowering travel.

As seen in Figure 3, the trip bar 377 also carries an air valve trip 436e which cooperates with an air valve 486 fixedly mounted on the machine frame. The air valve 486 is normally biased in a valve closed position and serves to control flow between a compressed air source line 488 and an air supply line 489 leading to the jawoperating cylinder 320 at an end thereof for effecting rearward movement of the piston rod 318 and consequent opening of the bottle gripping jaws.

Referring particularly to Figure 26 of the drawing, we have diagrammatically illustrated the electrical control circuit for effecting automatic and manual operation of the various machine functions. ln particular, our control circuit provides complete fail-safe operation of the machine under any condition of mechanical or pneumatic malfunctioning.

In Figure 27, a diagrammatic view of the front end of the case loader is shown for the purpose of illustrating the particular mounting position of the various electrical switches, wiring elements, and other electrical control devices. A rst large box 510 is provided on the front side of the case feed conveyor housing. Within the box 51d are positioned a pair of motor starters 502 and 504 for the bottle conveyor and case feed conveyor motors 108 and 44d, respectively. A manual disconnect switch 506 extends from the box 510, and permits the machine operator to connect or disconnect the machine from its.

electrical power supply. A transformer is carried within the box 510, and serves to provide a current of reduced voltage to the various electrical controls and solenoids.

A second control box 52) is mounted upon the casefeed conveyor frame above the case ap guide 437. The box 52@ provides various manual control buttons for regulating the machine operation to permit clearing of the machine in the event of bottle or debris jamming. Box 520 provides an elevator-up button 522, and a red pilot light 528 which is connected to the full pattern limit switch 246 to permit lighting when the bottle pattern is not complete and switch 246 is open.

A third control box 536) is also mounted on the casefeed conveyor. The box 536 provides an additional group of manual controls including a conveyor start button 532, a conveyor stop button 534, a case feed button 536, and a cycle button 53S for shutting 0E the controls.

A fourth control box 540 is mounted at the top of the machine frame above the bottle gripping head assembly. The box 54d encloses a relay 542 and a terminal mounting strip which permits wiring of the various limit switches at a position for convenient access.

Referring again to the circuit diagram of Figure 26 we have indicated a plurality of solenoids which serve to actuate the various valves for controlling the operation of the pneumatic cylinders which elect guide `plate swing` 

